Waterborne epoxy coating composition and method

ABSTRACT

A waterborne coating composition comprising a waterborne epoxy coating with hydraulic cement, which is capable of a thin initial application. The coating composition may be made, stored and transported as a two-part composition, where each part is a pourable liquid. The waterborne epoxy composition cures under normal conditions and adheres to surfaces including masonry, concrete and metal.

RELATED APPLICATIONS

The present application is a continuation and claims priority benefit ofan earlier-filed application of the same title, Ser. No. 11/018,644,filed Dec. 20, 2004. The identified earlier-filed application is herebyincorporated by reference into the present application.

FIELD OF THE INVENTION

This invention relates to coating compositions and, more particularly,to waterborne epoxy coating compositions and methods for using suchcompositions.

BACKGROUND OF THE INVENTION

Epoxy coating compositions are used to treat surfaces to protect againstcorrosion and other forms of wear and tear caused by use and theenvironment. The types of surfaces treated include concrete, metal, andother surfaces. Effective coating compositions are prized not only forthe quality of protection, but also for easy and efficienttransportation, storage, and application. Thus, a good coatingcomposition will not only protect the surface, but also be easy to applyand quick to cure.

The use of epoxy compositions containing volatile organic solvents hasfallen out of favor even though these compositions provide exceptionalanti-corrosion protection. The organic solvent based compositions areenvironmentally unfriendly and their use has been curtailed. Solventfree epoxy coatings often require sophisticated, non-standard equipmentfor application.

Other epoxy coating compositions provide good protection if applied atthe recommended thickness. This recommended thickness requires multiplecoats and each coat must be cured or set before another coat may beapplied. Each additional coat requires additional labor, which increasesthe cost of application. Other coats may be applied at greater initialthickness, but require more time to set up. Coatings applied at greaterinitial thicknesses may also introduce flaws caused by voids fromevaporation of volatile components during the curing process.

The combination of an epoxy resin and cement in a coating compositionhas been used previously to create cement compositions suitable foroverlaying concrete. For example, prior products include cement basedcompositions with an epoxy used as “mortars,” “toppings,” or “overlays”to coat Portland cement concrete or metal surfaces. These compositionsuse a small portion of epoxy to enhance the cement composition and thefinal compositions are thick like cement and resembles cement. These aregenerally two-component compositions having a dry-mix component and awet-mix component which are combined to form the final composition forapplication to surfaces in thick films, typically greater than about 20mils. Other compositions have used an epoxy to bind a cementcomposition.

BRIEF SUMMARY OF THE INVENTION

There is, therefore, provided in the practice of the invention a novelwaterborne fluid coating composition, which is epoxy based and includeshydraulic cement, for reduced initial thickness application, and whichprovides for a quicker application at a reduced cost. The waterborneepoxy coating composition broadly includes an epoxy resin, a hydrauliccement powder, a curing agent and water.

In one embodiment, the coating composition is prepared by mixing twopre-blended liquid components; one component containing a liquid epoxyresin and hydraulic cement powder; and the other component containing anamine-based curing agent and water. The first part may also includeadditives, such as a non-reactive diluent, a reactive diluent, anorganosilicon adhesion promoter, a pigment, hollow spheres, or othermaterials. The second part may also include additives, such as a cementplasticizer, a non-reactive diluent, a water-based latex resin, adefoamer, a corrosion inhibitor, or other materials.

Accordingly, it is an object of the present invention to provide animproved two-part waterborne epoxy coating providing anti-corrosionprotection.

DETAILED DESCRIPTION

The waterborne epoxy composition broadly includes an epoxy resin, cementpowder, an amine-based curing agent, and water. The composition may beenhanced with additives, including a non-reactive diluent, a reactivediluent, an organosilicon adhesion promoter, a pigment, hollow spheres,a cement plasticizer, a water-based latex resin, a defoamer, a corrosioninhibitor, or other materials Each element of the general formula willbe discussed in detail below, followed by several embodiments of thecomposition and the method of production and application.

In various embodiments of the invention, the epoxy resin is present inthe composition in an amount of about 8.0% to about 23.0% by weight,preferably about 10.0% to about 21.0% by weight, and more preferablyabout 11.0% to about 19.0% by weight.

The epoxy resin may be liquid, solid or semi-solid. The epoxy resinfunctions as the curable component of one part of the two-part epoxycoating composition. In one embodiment, the epoxy resin may consist ofany one of bisphenol A, bisphenol F, epoxy phenol novolac, epoxy cresolnovolac, naphthalene epoxy, or tertiary butyl cathecol epoxy. Anotherepoxy may be used besides those listed here, although these arepreferred. In exemplary embodiments, the epoxy resin is a liquidbisphenol A epoxy resin, including for example, liquid bisphenol A epoxyresin such as Huntsman GY6010, or a water-dispersed bisphenol A epoxyresin such as Resolution EPI-REZ 3510-W-60.

In various embodiments of the invention, hydraulic cement powder ispresent in the composition in an amount of about 20.0% to about 72.0% byweight, preferably about 28.0% to about 71.0% by weight, and morepreferably about 30.0% to about 70.0% by weight.

The hydraulic cement powder may be any type of Portland cement and mayalso be any color. Portland cement comes in Types I, II, III, IV, and V.The possible colors include white, grey, etc. In another embodiment, thehydraulic cement powder is a mixture of 0.50 to 0.95 weight parts ofPortland Cement and 0.05 to 0.50 weight parts pozzolan powder derivedfrom a group comprising fly ash, steel slag, silica fume, or calcinedkaolin clay.

In various embodiments of the invention, the curing agent is present inthe composition in an amount of about 5.0% to about 21.0% by weight,preferably about 7.0% to about 19.0% by weight, and more preferablyabout 8.0% to about 18.0% by weight.

The curing agent may be a substantially solvent free, or a waterdilutable polyamine having a plurality of N—H linkages capable ofreacting with the epoxy resin. The amine-based curing agent may be apolyoxyalkylene polyamine, arylene polyamine, cyclo-aliphatic polyamine,Mannich base, or a blend of two or more of these polyamines. An exampleof a solvent free amine curing agent used in an embodiment is apolyoxypropylene polyamine such as Huntsman JEFFAMINE D-400. Examples ofcommercially available water-based amine curing agents useful in theinvention include, for example, Cognis WATERPOXY 751, UCB BECKOPOX 613,Huntsman ARADUR 39, Bakelite RUETADUR VE-51, and Air Products ANQUAMINE287. Preferably, the curing agent is a water soluble polyamine adductcontaining a grafted internal reactive surfactant on the backbone,containing primary, secondary and tertiary amine functionality with somefree monomeric polyamine, enabling the emulsification of liquid epoxyresin, without addition of external surfactant, and that is misciblewith water in all proportions, such as Cognis WATERPOXY 751, asdisclosed in U.S. Pat. No. 6,395,806.

The coating compositions of the invention are prepared from a desiredamount of epoxy resin such that the weight ratio of epoxy resin tohydraulic cement is in the range of about 0.1:1 to about 1.2:1; thecompositions further provide a ratio of about 0.8 to 1.3 equivalents oftotal epoxy groups to 1.0 equivalent of reactive curing agent aminegroups; and 0.2 to 0.9 parts water to 1.0 part hydraulic cement.

A non-reactive diluent may be added to decrease the viscosity of themixture. Any diluent that does not react with the other elements of thecomposition and decreases viscosity may be used. In one embodiment, thenon-reactive diluent is benzyl alcohol, which not only reducesviscosity, but also speeds the epoxy/amine reaction and helps preventfreezing or crystallization of the coating composition. In anotherembodiment, the non-reactive diluent is an aromatic hydrocarbon resin,such as Rütgers NOVARES LS 500 for example, which not only reducesviscosity, but also has lower volatility. The non-reactive diluent maybe included in either or both components of the composition.

The composition may further include a reactive diluent. The reactivediluent may be an aliphatic, cycloaliphatic, or aromatic epoxyfunctional diluent. The reactive diluent may be either monofunctional ormultifunctional. In one embodiment, the reactive diluent is a C6 to C18alkyl mono glycidyl ether, and is included at a ratio of about 8 to 26parts per 100 parts of epoxy resin. One example of a commercial reactivediluent suitable for this composition is Air Products EPODIL 748.

The composition may further include an organosilicon adhesion promoterto enhance the adhesion of the cured composition to the surface beingcoated. The organosilicon adhesion promoter is included in a ratio ofabout 0.5 to 2 parts to 100 parts of epoxy resin. In one embodiment, theorganosilicon adhesion promoter is γ-glycidoxypropyl-trimethoxy silane.

The composition may further include a water-based latex resin in a ratioof up to about 1.2 parts water-based latex resin to 1.0 part ofhydraulic cement. Examples of useful water-based latex resins include,acrylic, styrene-acrylic, styrene butadiene rubber (SBR), polyvinylacetate (PVA), and ethylene vinyl acetate (EVA) latexes. In oneembodiment, the latex resin is an acrylic, styrene-acrylic, or styrenebutadiene rubber (SBR) latex. Examples include Rohm & Haas RHOPLEXMC-1834, SYNTHOMER 29Y46 SBR, and Resolution IC-780.

The composition may further include a desired amount of pigment up toabout 24.0% in order to achieve the desired coating color. In oneembodiment the pigment is titanium dioxide. The pigment may be dispersedin either component of the two-part composition of the invention.

The composition may further include up to about 8.0%, preferably about1.0% to about 8.0%, by weight hollow spheres as an inert filler. In oneembodiment the hollow spheres are hollow micro-spheres having a particlediameter in the range of about 5 to 90 microns and are included in thehydraulic cement containing component of the two-part composition in aratio of about 1 part hollow spheres to about 3 to 50 parts of hydrauliccement. Examples include 3M SCOTCHLITE K37 Glass Bubbles and CHL A-90Hollow Ceramic Microspheres.

The composition may further include up to about 0.4% of a cementplasticizer, such as a lignosulfonate salt, for example Lignotech Norlig24C; up to about 0.55% of a defoamer, such as a non-silicone defoamer,for example BYK-Chemie BYK-011, and/or a silicone defoamer, for exampleTego FOAMEX 805; and up to about 2.4% of a corrosion inhibitor, such asCortec MCI-2000 or W. R. Grace DCI S; all as set forth in the followingexamples and claims.

Thus, in various embodiments, the composition of the present inventionincludes some or all of the following components: about 0.06% to about0.40% by weight of a concrete plasticizer; about 0.15% to about 0.55% byweight of a defoamer; and, about 0.01% to about 2.4% by weight of acorrosion inhibitor.

One embodiment of the waterborne epoxy coating composition is dividedinto two parts for easy storage and transportation. Part A of thisformula is non-aqueous and includes liquid Bisphenol A epoxy resin,reactive diluent, organosilicon adhesion promoter, hydraulic cement, andhollow spheres. Part B is aqueous and includes water-based amine curingagent, water-based latex resin, and defoamer. The two parts are combinedin a sprayer to mix the two parts together and then apply the coatingcomposition to a surface, wherein the composition has a weight ratio ofepoxy resin to hydraulic cement in the range of about 0.19:1 to about0.6:1; a ratio of about 0.9 to 1.15 equivalents of total epoxy groups to1.0 equivalent of reactive curing agent amine groups; and 0.3 to 0.6parts total water to 1.0 part hydraulic cement.

Another embodiment comprises a non-aqueous Part A including liquidBisphenol A epoxy resin, reactive diluent, organosilicon adhesionpromoter, hydraulic cement, and hollow spheres; and an aqueous Part Bincluding a water-based amine curing agent, water-based latex resin, anddefoamer. The two parts are combined in a sprayer to mix the two partstogether and then apply the coating composition to a surface, whereinthe final composition has a weight ratio of epoxy resin to hydrauliccement is in the range of about 0.25:1 to about 0.5:1; a ratio of about0.95 to 1.1 equivalents of total epoxy groups to 1.0 equivalent ofreactive curing agent amine groups; and 0.4 to 0.6 parts total water to1.0 part hydraulic cement. Each part is approximately equal in volumeand additional water may be added after the two parts are mixed.

Various embodiments of the non-aqueous Part A of the two partcomposition of the invention broadly comprise some or all of thefollowing components: epoxy resin in an amount of about 10% to about 42%by weight, preferably about 15% to about 33% by weight, and morepreferably about 18% to about 27% by weight of said Part A; hydrauliccement powder in an amount of about 46% to about 90% by weight,preferably about 57% to about 84% by weight, and more preferably about58% to about 80% by weight of said Part A; hollow spheres in an amountof about 1% to about 13% by weight of said Part A; mono glycidyl etheras reactive diluent in an amount of about 1.1% to about 4.8% by weightof said Part A; and an organosilicon adhesion promoter in an amount ofabout 0.1% to about 0.5% by weight, preferably about 0.2% to about 0.4%by weight of said Part A. Various embodiments of the aqueous Part B ofthe two part composition of the invention broadly comprise some or allof the following components: at least one curing agent, comprising awater soluble polyamine, in an amount of about 30% to about 60% byweight, preferably about 34% to about 52% by weight of said Part B;concrete plasticizer in an amount of about 0.2% to about 0.6% by weightof said Part B; water-based latex resin in an amount of about 30% toabout 50% by weight of said Part B; defoamer in an amount of about 0.5%to about 1.0% by weight of said Part B; and corrosion inhibitor in anamount of about 0.04% to about 18.5% by weight of said Part B. Furtherexemplary embodiments are set forth in the following examples.

In an alternative embodiment the non-aqueous Part A includes asolvent-free amine curing agent, hydraulic cement and hollow spheres.Part B is aqueous and includes a water-dispersed epoxy resin, and mayfurther contain a water-based latex resin, and defoamer. The two partsare combined in a sprayer to mix the two parts together and then applythe coating composition to a surface, wherein the composition has aweight ratio of epoxy resin to hydraulic cement in the range of about0.1:1 to about 1.2:1; a ratio of about 0.8 to 1.3 equivalents of totalepoxy groups to 1.0 equivalent of reactive curing agent amine groups;and 0.2 to 0.9 parts total water to 1.0 part hydraulic cement.

The embodiments of the waterborne epoxy coating composition may beapplied with a brush, roller, or airless sprayer to produce curedcoatings with a thickness from about 78% to about 95% of the single coatwet thickness. Exemplary embodiments of the composition applied byairless sprayer produce cured coatings with a thickness from about 90%to about 95% of the single coat wet thickness. Said cured coatings havea thickness of from approximately 2 mils to approximately 15 mils,preferably having a thickness of approximately 4 mils to approximately12 mils, and more preferably having a thickness of approximately 6 milsto approximately 10 mils. The embodiments of the composition exhibit geltimes from about 60 minutes to about 120 minutes and are dry to touch inless than 24 hours.

The embodiments of the composition are more specifically shown in thefollowing examples, wherein it can be seen that the embodiments of thecomposition are prepared without the use of a separate emulsifiersurfactant to stabilize either part of the two part composition or thefinal blended composition. It is further apparent from the foregoingdetailed description and the component ranges from the followingexamples of embodiments of the composition of the invention that thecomposition has low volatile organic compound content, generally notmore than about 3.3% by weight of the total composition, preferably notmore than about 2.2% by weight of the total composition, and morepreferably not more than about 2% by weight of total composition, asindicated by the non-reactive diluent (benzyl alcohol) content.

Examples 1 2 3 Weight % Weight % Weight % Part A Components Epoxy ResinHuntsman GY6010 22.29 20.35 23.26 Reactive Diluent Air Products Epodil748 2.50 2.29 2.61 Adhesion Promoter OSi Silquest A-187 0.25 0.23 0.26Portland Cement Lehigh Type I 59.43 0 0 Lefarge Fondu Type V 0 66.4350.32 Pozzolan Lefarge NewChem Slag 0 0 16.70 Titanium Dioxide HuntsmanTR-60 9.60 0 0 Hollow Spheres 2.50 7.59 3.27 Non-reactive Diluent BenzylAlcohol 3.42 3.12 3.57 Total Part A 100.00 100.00 100.00 Part BComponents Water-based amine curing Cognis Waterpoxy 751 14.95 25.6451.87 agent Anquamine 287 35.33 10.85 0 Titanium Dioxide Huntsman TR-6027.82 0 Concrete Super Plasticizer Lignotech Norlig 24C 0.57 0 0 LatexEmulsion Synthomer 29Y46 SBR 48.61 0 0 Rohm & Haas Rhoplex MC- 0 35.28 01834 Non-reactive Diluent Benzyl Alcohol 0.55 0.40 0 Deionized Water 0 029.95 Corrosion Inhibitor W. R. Grace DCI S 0 0 18.18 Total Part B100.00 100.00 100.00 Examples 4 5 6 7 8 9 10 Weight % Weight % Weight %Weight % Weight % Weight % Weight % Part A Components Epoxy Resin: 13.0413.45 12.20 14.44 10.55 16.47 8.23 Huntsman GY6010 Reactive Diluent: Air1.46 1.51 1.37 1.62 1.19 1.85 0.92 Products Epodil 748 AdhesionPromoter: 0.15 0.15 0.14 0.16 0.12 0.19 0.09 OSi Silquest A-187 PortlandCement: 35.82 37.44 38.90 34.12 43.08 26.68 42.67 Lefarge Secar 71 TypeV Pozzolan: Calcined 7.18 3.74 7.78 2.73 10.77 1.33 21.34 Kaolin ImerysMetastar 450 Hollow Spheres: 3M 2.34 2.42 2.19 2.60 1.90 2.96 1.48Scotchlite K37 Non-reactive Diluent: 2.00 2.07 1.87 2.22 1.62 2.53 1.26Benzyl Alcohol Sub-total 61.99 60.78 64.45 57.9057.89 69.23 52.01 75.99Part B Components Water-based amine 16.49 17.01 15.42 18.26 13.35 20.8210.41 curing agent: Cognis Waterpoxy 751 Deionized Water 4.74 4.90 4.445.26 3.84 5.99 3.00 Latex Emulsion: 16.27 16.78 15.22 18.02 13.17 20.5410.27 Rohm & Haas Rhoplex MC-1834 Non-reactive Diluent: 0.18 0.19 0.170.20 0.15 0.23 0.12 Benzyl Alcohol Defoamer: BYK- 0.33 0.34 0.31 0.360.26 0.41 0.21 Chemie BYK-011 (non-silicone) Sub-total 38.01 39.22 35.5642.10 30.77 47.99 24.01 Examples 11 12 13 14 15 16 17 Weight % Weight %Weight % Weight % Weight % Weight % Weight % Part A Components EpoxyResin: Huntsman 11.48 13.16 11.74 12.82 10.43 14.86 8.53 GY6010 ReactiveDiluent: Air 1.29 1.48 1.32 1.44 1.17 1.67 0.96 Products Epodil 748Adhesion Promoter: OSi 0.13 0.15 0.13 0.14 0.12 0.17 0.10 Silquest A-187Portland Cement: 32.41 27.48 31.44 29.65 35.75 20.20 36.52 Lefarge Secar71 Type V Pozzolan: Fly Ash 6.71 2.75 6.29 2.37 8.94 1.01 18.26 HollowSpheres: 3M 4.27 4.90 4.37 4.77 3.88 5.53 3.17 Scotchlite K37Non-reactive Diluent: 1.76 2.02 1.80 1.97 1.60 2.28 1.31 Benzyl AlcoholSub-total 58.05 51.93 57.10 53.17 61.89 45.72 68.85 Part B ComponentsWater-based amine 14.52 16.64 14.85 16.21 13.19 18.79 10.78 curingagent: Cognis Waterpoxy 751 Deionized Water 1.35 1.55 1.38 1.51 1.231.75 1.00 Titanium Dioxide: 11.3 12.95 11.55 12.61 10.26 14.62 8.39Huntsman TR-60 Latex Emulsion: Rohm 14.33 16.42 14.65 16.00 13.02 18.5410.64 & Haas Rhoplex MC- 1834 Non-reactive Diluent: 0.16 0.19 0.17 0.180.15 0.21 0.12 Benzyl Alcohol Defoamer: BYK- 0.29 0.33 0.29 0.32 0.260.37 0.21 Chemie BYK-011 (non- silicone) Sub-total 41.95 48.07 42.9046.83 38.11 54.28 31.15 Examples 18 19 20 21 22 23 24 Weight % Weight %Weight % Weight % Weight % Weight % Weight % Part A Components EpoxyResin: Huntsman 13.20 13.85 12.62 14.81 10.99 16.76 8.73 GY6010 ReactiveDiluent: Air 1.48 1.56 1.42 1.66 1.23 1.88 0.98 Products Epodil 748Adhesion Promoter: OSi 0.15 0.16 0.14 0.17 0.12 0.19 0.10 Silquest A-187Portland Cement: 34.91 35.51 37.07 32.24 41.32 25.01 41.05 Lefarge FonduType V Pozzolan: Lefarge 7.00 3.55 7.41 2.58 10.33 1.25 20.53 NewChemSlag Hollow Spheres: 3M 5.06 5.31 4.83 5.67 4.21 6.42 3.35 ScotchliteK37 Non-reactive Diluent: 2.03 2.13 1.94 2.27 1.69 2.57 1.34 BenzylAlcohol Sub-total 63.83 62.05 65.43 59.41 69.89 54.08 76.07 Part BComponents Water-based amine 16.07 16.86 15.36 18.03 13.38 20.40 10.63curing agent: Cognis Waterpoxy 751 Deionized Water 3.83 4.02 3.66 4.303.19 4.86 2.53 Latex Emulsion: 15.77 16.55 15.08 17.70 13.13 20.02 10.43Synthomer 29Y46 SBR Non-reactive Diluent: 0.18 0.19 0.17 0.20 0.15 0.230.12 Benzyl Alcohol Defoamer: BYK- 0.32 0.33 0.30 0.36 0.27 0.40 0.21Chemie BYK-011 (non- silicone) Sub-total 36.17 37.95 34.57 40.59 30.1145.92 23.93 Examples 25 26 27 28 29 30 31 Weight % Weight % Weight %Weight % Weight % Weight % Weight % Part A Components Epoxy Resin:Huntsman 11.81 13.16 12.16 13.92 10.80 15.40 8.82 GY6010 ReactiveDiluent: Air 1.33 1.48 1.37 1.56 1.21 1.73 0.99 Products Epodil 748Adhesion Promoter: OSi 0.13 0.15 0.14 0.16 0.12 0.17 0.10 Silquest A-187Portland Cement: 33.32 29.83 31.59 26.78 35.90 20.33 36.65 Lefarge Secar71 White Type V (Calcium Aluminate) Pozzolan: Silica Fume 6.66 2.98 6.322.14 8.97 1.02 18.32 Hollow Spheres: 3M 1.81 2.01 1.86 2.13 1.65 2.361.35 Scotchlite K37 Non-reactive Diluent: 1.81 2.02 1.87 2.14 1.66 2.371.35 Benzyl Alcohol Sub-total 56.87 51.63 55.30 48.83 60.31 43.37 67.58Part B Components Water-based amine 14.93 17.07 15.77 18.05 14.00 19.9811.44 curing agent: Cognis Waterpoxy 751 Deionized Water 1.39 0.65 0.610.69 0.54 0.77 0.44 Titanium Dioxide: 11.62 13.28 12.27 14.05 10.9015.55 8.90 Huntsman TR-60 Latex Emulsion: Rohm 14.73 16.84 15.56 17.8113.82 19.72 11.29 & Haas Rhoplex MC- 1834 Non-reactive Diluent: 0.170.19 0.18 0.20 0.16 0.22 0.13 Benzyl Alcohol Defoamer: BYK-Chemie 0.300.34 0.31 0.36 0.28 0.40 0.23 BYK-011 (non-silicone) Sub-total 43.1348.37 44.70 51.17 39.69 56.63 32.42 Examples 32 33 34 35 36 37 38 Weight% Weight % Weight % Weight % Weight % Weight % Weight % Part AComponents Epoxy Resin: Huntsman 13.23 13.65 12.37 14.66 10.70 16.728.43 GY6010 Reactive Diluent: Air 1.49 1.53 1.39 1.65 1.20 1.88 0.95Products Epodil 748 Adhesion Promoter: OSi 0.15 0.15 0.14 0.16 0.12 0.190.09 Silquest A-187 Portland Cement: 35.89 37.53 38.98 34.20 43.16 26.7542.49 Federal Type I Pozzolan: Calcined 7.20 3.75 7.80 2.74 10.79 1.3421.25 Kaolin Imerys Metastar 450 Hollow Spheres: 3M 1.93 1.99 1.80 2.131.56 2.43 1.23 Scotchlite K37 Non-reactive Diluent: 2.03 2.10 1.90 2.251.64 2.57 1.29 Benzyl Alcohol Sub-total 61.921 60.70 64.38 57.79 69.1851.87 75.73 Part B Components Water-based amine 16.52 17.05 15.45 18.3113.37 20.88 10.53 curing agent: Cognis Waterpoxy 751 Deionized Water4.76 4.91 4.45 5.27 3.85 6.01 3.03 Latex Emulsion: Rohm 16.30 16.8215.25 18.06 13.19 20.60 10.39 & Haas Rhoplex MC- 1834 Non-reactiveDiluent: 0.18 0.19 0.17 0.20 0.15 0.23 0.12 Benzyl Alcohol Defoamer:BYK- 0.33 0.34 0.31 0.36 0.27 0.41 0.21 Chemie BYK-011 (non- silicone)Sub-total 38.09 39.30 35.62 42.21 30.82 48.13 24.27 Examples 39 40 41 4243 44 45 Weight % Weight % Weight % Weight % Weight % Weight % Weight %Part A Components Epoxy Resin: Huntsman 13.07 13.49 12.23 14.49 10.5816.52 8.33 GY6010 Reactive Diluent: Air 1.47 1.52 1.37 1.63 1.19 1.860.94 Products Epodil 748 Adhesion Promoter: OSi 0.15 0.15 0.14 0.16 0.120.19 0.09 Silquest A-187 Portland Cement: 35.91 37.55 39.00 34.23 43.1826.77 42.51 Federal Type I Pozzolan: Lefarge 7.20 3.75 7.80 2.74 10.791.34 21.25 NewChem Slag Hollow Spheres: 3M 2.08 2.14 1.94 2.30 1.68 2.631.32 Scotchlite K37 Non-reactive Diluent: 2.01 2.07 1.88 2.22 1.62 2.541.28 Benzyl Alcohol Sub-total 61.89 60.68 64.36 57.77 69.16 51.83 75.72Part B Components Water-based amine 16.53 17.06 15.46 18.32 13.37 20.8910.53 curing agent: Cognis Waterpoxy 751 Deionized Water 4.76 4.91 4.455.27 3.85 6.01 3.03 Latex Emulsion: Rohm 16.31 16.83 15.25 18.07 13.2020.61 10.39 & Haas Rhoplex MC- 1834 Non-reactive Diluent: 0.18 0.19 0.170.20 0.15 0.23 0.12 Benzyl Alcohol Defoamer: BYK- 0.33 0.34 0.31 0.360.27 0.41 0.21 Chemie BYK-011 (non- silicone) Sub-total 38.11 39.3235.64 42.23 30.84 48.17 24.28 Examples 46 47 48 49 50 51 52 Weight %Weight % Weight % Weight % Weight % Weight % Weight % Part A ComponentsEpoxy Resin: Huntsman 13.11 13.53 12.26 14.53 10.60 16.58 8.34 GY6010Reactive Diluent: Air 1.47 1.52 1.38 1.63 1.19 1.86 0.94 Products Epodil748 Adhesion Promoter: OSi 0.15 0.15 0.14 0.16 0.12 0.19 0.09 SilquestA-187 Portland Cement: 36.02 37.66 39.10 34.33 43.28 26.86 42.58 FederalType I Pozzolan: Silica Fume 7.22 3.77 7.82 2.75 10.82 1.34 21.29 HollowSpheres: 3M 1.80 1.86 1.68 2.00 1.46 2.28 1.15 Scotchlite K37Non-reactive Diluent: 2.01 2.08 1.88 2.23 1.63 2.55 1.28 Benzyl AlcoholSub-total 61.78 60.56 64.26 57.64 69.09 51.66 75.68 Part B ComponentsWater-based amine 16.58 17.11 15.50 18.38 13.41 20.97 10.55 curingagent: Cognis Waterpoxy 751 Deionized Water 4.77 4.92 4.46 5.29 3.866.03 3.04 Latex Emulsion: Rohm 16.36 16.88 15.29 18.13 13.23 20.69 10.41& Haas Rhoplex MC- 1834 Non-reactive Diluent: 0.18 0.19 0.17 0.20 0.150.23 0.12 Benzyl Alcohol Defoamer: BYK- 0.33 0.34 0.31 0.36 0.27 0.420.21 Chemie BYK-011 (non- silicone) Sub-total 38.22 39.44 35.74 42.3630.91 48.34 24.32 Examples 53 54 55 56 57 58 59 Weight % Weight % Weight% Weight % Weight % Weight % Weight % Part A Components Epoxy Resin:12.12 13.51 12.49 14.29 11.09 15.81 9.62 Huntsman GY6010 ReactiveDiluent: Air 1.36 1.52 1.40 1.61 1.25 1.73 1.08 Products Epodil 748Adhesion Promoter: 0.14 0.15 0.14 0.16 0.12 0.18 0.11 OSi Silquest A-187Portland Cement: Type I 39.58 32.67 37.76 28.80 44.72 21.23 58.20 HollowSpheres: 3M 2.28 2.54 2.35 2.68 2.08 2.97 1.81 Scotchlite K37Non-reactive Diluent: 1.86 2.07 1.92 2.19 1.70 2.43 1.48 Benzyl AlcoholSub-total 57.34 52.46 56.06 49.73 60.97 44.39 72.29 Part B ComponentsWater-based amine 4.63 5.16 4.77 5.45 4.23 6.03 3.01 curing agent:Anquamine 287 Water-based amine 10.93 12.18 11.26 12.89 10.00 14.26 7.10curing agent: Waterpoxy 751 Titanium Dioxide: 11.86 13.22 12.22 13.9810.85 15.47 7.71 Huntsman TR-60 Latex Emulsion: 15.05 16.77 15.50 17.7313.77 19.61 9.77 Synthomer 29Y46 SBR Non-reactive Diluent: 0.17 0.190.18 0.20 0.16 0.22 0.11 Benzyl Alcohol Corrosion Inhibitor: 0.02 0.020.02 0.02 0.02 0.02 0.01 Cortec MCI-2000 Sub-total 42.66 47.54 43.9450.27 39.03 55.61 27.71

Further embodiments of the composition are described by the followinguntested examples. The following examples are provide by way ofillustration not limitation, and the changes reflected are equallyapplicable to each of the compositions specifically described inExamples 1 through 59.

Untested Examples 60 61 62 63 64 Weight % Weight % Weight % Weight %Weight % Part A Components Epoxy Resin Huntsman GY6010 14.31 13.04 13.0411.48 12.12 Reactive Diluent Air Products Epodil 1.61 1.46 1.46 1.291.36 748 Adhesion OSi Silquest A-187 0.16 0.15 0.15 0.13 0.14 PromoterPortland Cement Type I 38.15 0 0 0 39.58 Type V 0 35.82 35.82 32.41 0Pozzolan Calcined Kaolin 0 7.18 7.18 0 0 Fly Ash 0 0 0 6.71 0 TitaniumDioxide Huntsman TR-60 6.16 0 0 0 0 Hollow Spheres 1.61 2.34 2.34 4.272.28 Non-reactive Rutgers Novares LS 2.20 2.00 2.00 1.76 1.86 Diluent500 Sub-total 64.19 61.99 61.99 58.06 57.34 Part B ComponentsWater-based amine Cognis Waterpoxy 5.35 16.49 16.49 14.52 10.93 curingagent 751 Anquamine 287 12.65 0 0 0 4.63 Deionized Water 4.74 4.74 1.350 Titanium Dioxide Huntsman TR-60 0 0 0 11.30 11.86 Concrete SuperLignotech Norlig 24C 0.20 0 0 0 0 Plasticizer Latex Emulsion Synthomer29Y46 17.41 0 0 0 15.05 SBR Rohm & Haas 0 16.27 16.27 14.33 0 RhoplexMC-1834 Non-reactive Benzyl Alcohol 0 0.18 0 0 0 Diluent Rutgers NovaresLS 0.2 0 0.18 0.16 0.17 500 Defoamer BYK-Chemie BYK- 0 0 0.16 0 0 011(non-silicone) Tego Foamex 805 0 0.33 0.17 0.29 0 (silicone) CorrosionInhibitor Cortec MCI-2000 0 0 0 0 0.02 Sub-total 35.81 38.01 38.01 41.9442.66 Untested Examples 65 Weight % Part A Components Liquid Amine ResinHuntsman Jeffamine D-400 14.45 Portland Cement Lehigh Type I 42.01Hollow Spheres Scotchlite K-37 Glass Bubbles 2.41 Sub-total 58.86 Part BComponents Water-dispersed Epoxy Resin Resolution Epi-Rez 3510-W-6041.14 Sub-total 41.14

Thus, in various embodiments, the composition of the present inventionbroadly comprises some or all of the following components: an epoxyresin of, in one embodiment, between 8.0% to 23.0% by weight, and, inanother embodiment, between 10% to 42% by weight; a powdered hydrauliccement of, in one embodiment, between 20.0% to 72.0% by weight and, inanother embodiment, between 46% to 90% by weight; water in an amount atleast sufficient to react with the cement; a curing agent of, in oneembodiment, between 5.0% to 21.0% by weight, and, in another embodiment,between 30% to 60%; a non-reactive diluent of between 0.1% to 3.3% byweight; a reactive diluent of, in one embodiment, between 0.8% to 2.6%by weight, and, in another embodiment, between 1.1% to 4.8% by weight; apigment of between 6.0% to 24.0% by weight; an organosilicon adhesionpromoter of, in one embodiment, between 0.08% to 0.26% by weight, and,in another embodiment, between 0.1% to 0.5%; a water-based latex resinof between 4.0% to 31.0% by weight; a plurality of hollow spheres of, inone embodiment, between 1.0% to 8.0% by weight, and, in anotherembodiment, between 1% to 13% by weight; a defoamer of between 0.5% to1.0% by weight; a non-silicon defoamer of between 0.15% to 0.55% byweight; a silicone defoamer of between 0.15% to 0.55% by weight; acorrosion inhibitor of, in one embodiment, between 0.01% to 2.4% byweight, and, in another embodiment, of between 0.04% to 18.5% by weight;a concrete plasticizer of between 0.2% to 0.6% by weight; and/or a latexresin of between 30% to 50% by weight. Characterized another way, oneembodiment of the composition of the present invention broadly comprisesapproximately 90 parts epoxy resin mixed with approximately 10 partsreactive diluent to produce a mixture, and approximately 1 parthydraulic cement powder mixed with approximately 0.11 to 1.5 parts ofthe aforementioned mixture, to ultimately produce the coatingcomposition having between 0.80 to 1.30 equivalents of total epoxygroups to 1.00 equivalent of reactive amine groups. In variousembodiments, the composition forms a coat having a thickness ofapproximately between 2 mils to 15 mils.

Any of the disclosed embodiments of the claimed composition may be usedin a process to protectively coat a surface. The process involvespreparing the composition according to the present invention, mixing thetwo parts with an appropriate amount of water, and applying the coatingto the surface. The formula may be applied with a brush, roller orairless sprayer and will achieve a high build film in a singleapplication, although multiple coats may be applied at the discretion ofthe user.

Thus, a waterborne epoxy composition is disclosed which utilizeshydraulic cement powder as an element of the epoxy composition toprovide a desired initial application coat thickness with good fluidityand enhanced cure time while still providing protection againstcorrosion and other environmental threats. The coating composition alsoprovides corrosion resistance equal to organic solvent based and solventfree coatings.

While preferred embodiments and particular applications of thisinvention have been shown and described, it is apparent to those skilledin the art that many other modifications and applications of thisinvention are possible, including using the teaching to develop coatingcompositions having three or more components, without departing from theinventive concepts herein. It is, therefore, to be understood that,within the scope of the appended claims, this invention may be practicedotherwise than as specifically described, and the invention is not to berestricted except in the spirit of the appended claims. Though some ofthe features of the invention may be claimed in dependency, each featurehas merit if used independently.

1. (canceled)
 2. A composition for use in coating surfaces with a thincoating, the composition comprising: (a) a desired amount of at leastone epoxy resin; (b) a desired amount of at least one mono glycidylether reactive diluent; (c) a desired amount of at least one powderedhydraulic cement; (d) at least one curing agent comprising a watersoluble polyamine composition capable of emulsifying the epoxy resin;(e) water in an amount at least sufficient to react with the powderedhydraulic cement; and (f) wherein the composition forms coatings havinga thickness of from approximately 2 mils to approximately 15 mils. 3.The composition according to claim 2, wherein the epoxy resin is aliquid epoxy resin comprising approximately 11.0% to 19.0% by weight ofthe total composition.
 4. The composition according to claim 3, whereinthe liquid epoxy resin is a liquid bisphenol A epoxy resin.
 5. Thecomposition according to claim 2, wherein the powdered hydraulic cementis Portland Cement comprising approximately 30.0% to 70.0% by weight ofthe total composition.
 6. The composition according to claim 2, whereinthe powdered hydraulic cement is a mixture of approximately 0.50 to 0.95weight parts of Portland Cement and approximately 0.05 to 0.50 weightparts pozzolan powder derived from a group comprising fly ash, steelslag, silica fume, or calcined kaolin clay.
 7. The composition accordingto claim 2, wherein the curing agent is a polyamine having a pluralityof N—H linkages capable of reacting with the epoxy resin comprisingapproximately 8.0% to 18.0% by weight of the total composition.
 8. Thecomposition according to claim 2, wherein the curing agent is apolyoxyalkylene polyamine.
 9. The composition according to claim 2,wherein the curing agent is an arylene polyamine.
 10. The compositionaccording to claim 2, wherein the curing agent is a cyclo-aliphaticpolyamine.
 11. The composition according to claim 2, wherein the curingagent comprises a blend of a Mannich base with polyoxyalkylenepolyamines, arylene polyamines, and cyclo-aliphatic polyamines.
 12. Thecomposition according to claim 2, wherein the curing agent comprises ablend of polyoxyalkylene polyamines, arylene polyamines, andcyclo-aliphatic polyamines.
 13. The composition according to claim 2,wherein the composition further includes approximately 0.1% to 3.3% byweight of a non-reactive diluent.
 14. The composition according to claim13, wherein the non-reactive diluent is benzyl alcohol.
 15. Thecomposition according to claim 13, wherein the non-reactive diluent isan aromatic hydrocarbon resin.
 16. The composition according to claim 2,wherein the mono glycidyl ether is present in an amount of approximately0.8% to 2.6% by weight of the composition.
 17. The composition accordingto claim 16, wherein the mono glycidyl ether is a C-6 to C-18 alkylglycidyl ether.
 18. The composition according to claim 16, wherein themono glycidyl ether is a C-12 to C-14 alkyl glycidyl ether.
 19. Thecomposition according to claim 2, wherein the composition furtherincludes approximately 6.0% to 24.0% by weight of a pigment.
 20. Thecomposition according to claim 19, wherein the pigment is titaniumdioxide.
 21. The composition according to claim 2, wherein thecomposition further includes approximately 0.08% to 0.26% by weight ofan organosilicon adhesion promoter.
 22. The composition according toclaim 21, wherein the organosilicon adhesion promoter isγ-glycidoxypropyl-trimethoxy silane.
 23. The composition according toclaim 2, wherein the composition further includes approximately 4.0% to31.0% by weight of a water-based latex resin.
 24. The compositionaccording to claim 23, wherein the water-based latex resin is astyrene-acrylic latex.
 25. The composition according to claim 23,wherein the water-based latex resin is a styrene butadiene rubber latex.26. The composition according to claim 23, wherein the water-based latexresin is an acrylic latex.
 27. The composition according to claim 2,wherein the composition further includes hollow spheres in an amount ofapproximately 1.0% to 8.0% by weight of the composition.
 28. Thecomposition according to claim 2, wherein the composition furtherincludes approximately 0.15% to 0.55% by weight of a non-siliconedefoamer.
 29. The composition according to claim 2, wherein thecomposition further includes approximately 0.15% to 0.55% by weight of asilicone defoamer.
 30. The composition according to claim 2, wherein thecomposition further includes approximately 0.01% to 2.4% by weight of acorrosion inhibitor
 31. The composition according to claim 2, whereinthe composition forms coatings having a thickness of from approximately4 mils to approximately 12 mils.
 32. The composition according to claim2, wherein the composition forms coatings having a thickness of fromapproximately 6 mils to approximately 10 mils.
 33. A paint compositionfor use in coating surfaces, the composition comprising: (a)approximately 10% to 42% by weight of an epoxy resin; (b) approximately46% to 90% by weight of hydraulic cement powder; (c) approximately 30%to 60% by weight of a curing agent comprising a water soluble polyaminecomposition capable of emulsifying the epoxy resin; (d) water in anamount at least sufficient to react with the hydraulic cement; (e)wherein the volatile organic compound content of the coating compositionis not more than approximately 3.3% by weight of the total composition;and (f) wherein the coating composition forms coatings having athickness of from approximately 2 mils to approximately 15 mils.
 34. Thecomposition according to claim 33, wherein the composition furtherincludes a desired amount of an inert filler.
 35. The compositionaccording to claim 34, wherein the inert filler comprises hollow spheresin an amount of approximately 1.0% to 8.0% by weight of the totalcomposition.
 36. The composition according to claim 33, wherein thecomposition is applied to a surface using a brush, roller or airlesssprayer to form a protective coating with a thickness of fromapproximately 6 mils to approximately 10 mils.
 37. The compositionaccording to claim 33, having a gel time of approximately 60 to 120minutes.
 38. The composition according to claim 33, having approximately0.8 to 1.3 equivalents of total epoxy groups to 1.0 equivalent ofreactive amine groups.
 39. The composition according to claim 33, havingapproximately 0.2 to 0.9 parts water to 1.0 part of hydraulic cement.40. A process for protecting a surface, the process comprising: (a)applying a fluid protective coating composition to the surface, thecoating composition comprising: (i) a desired amount of at least oneepoxy resin; (ii) a desired amount of at least one mono glycidyl etherreactive diluent; (iii) a desired amount of at least one powderedhydraulic cement; (iv) at least one curing agent in an amount sufficientto react with the epoxy resin; and (v) water in an amount at leastsufficient to react with the powdered hydraulic cement; and (b)permitting the coating composition to cure to form a protective coatingwith a thickness of from approximately 2 mils to approximately 15 mils.41. The process according to claim 40, wherein the composition isapplied to a surface using a brush, roller or airless sprayer to form aprotective coating with a thickness of from approximately 4 mils toapproximately 12 mils.
 42. The process according to claim 40, whereinthe composition is applied to a surface using a brush, roller or airlesssprayer to form a protective coating with a thickness of fromapproximately 6 mils to approximately 10 mils.
 43. The process accordingto claim 40, wherein the composition is applied in two coats.
 44. Theprocess according to claim 40, wherein the composition is applied inthree coats.
 45. The process according to claim 40, wherein thecomposition further includes: (a) mixing approximately 90 parts epoxyresin with approximately 10 parts mono glycidyl ether reactive diluent;(b) adding approximately 1 part hydraulic cement powder to approximately0.11 to 1.15 part epoxy mixture; and (c) adding approximately 1 parthollow spheres to approximately 3 to 50 parts of hydraulic cement powderto form a first component of said composition; (d) separately mixing atleast one curing agent, wherein the curing agent is a polyamine having aplurality of N—H linkages capable of reacting with the epoxy resin, witha desired amount of latex resin and water to form a second component ofsaid composition; and (e) combining the first component and the secondcomponent, in a ratio to provide a coating composition havingapproximately 0.8 to 1.3 equivalents of total epoxy groups to 1.0equivalent of reactive amine groups, in a conventional airless sprayer.46. The process according to claim 45, wherein the first component andthe second component are combined in a ratio to provide a coatingcomposition having approximately 0.9 to 1.1 equivalents of total epoxygroups to 1.0 equivalent of reactive amine groups.
 47. The processaccording to claim 45, wherein the first component and the secondcomponent are combined in a ratio to provide a coating compositionhaving approximately 0.2 to 0.9 parts water to 1.0 part of hydrauliccement.
 48. The process according to claim 45, wherein the firstcomponent and the second component are combined in a ratio to provide acoating composition having approximately 0.4 to 0.6 parts water to 1.0part of hydraulic cement.
 49. A composition for use in coating surfaceswith a thin coating, the composition comprising: (a) a desired amount ofat least one epoxy resin; (b) a desired amount of at least one powderedhydraulic cement; (c) a desired amount of at least one type of hollowspheres; (d) at least one curing agent in an amount sufficient to reactwith the epoxy resin; (e) water in an amount at least sufficient toreact with the powdered hydraulic cement; (f) wherein the compositiondoes not include a separate emulsifier surfactant; and (g) wherein thecomposition forms coatings having a thickness of from approximately 2mils to approximately 15 mils.
 50. A two-component composition for usein coating surfaces, the composition comprising: (a) a first componentincluding: (i) approximately 10% to 42% by weight of an epoxy resin; and(ii) approximately 46% to 90% by weight of hydraulic cement powder; and(b) a second component including: (i) approximately 30% to 60% by weightof a curing agent; and (ii) water in an amount at least sufficient toreact with the hydraulic cement; and (c) the first component and secondcomponent being mixed to provide the coating composition having a geltime of approximately 60 minutes to approximately 120 minutes, whereinthe coating composition forms coatings having a thickness of fromapproximately 2 mils to approximately 15 mils.
 51. The compositionaccording to claim 50, wherein the curing agent includes primary,secondary, and tertiary amine functionality.
 52. The compositionaccording to claim 50, wherein the curing agent is a diamine.
 53. Atwo-component composition for use in coating surfaces, the compositioncomprising: (a) an aqueous first component including: (i) a desiredamount of at least one water dispersed epoxy resin; (ii) a desiredamount of at least one latex resin; (iii) a desired amount of water; and(b) a non-aqueous second component including: (i) a desired amount of atleast one liquid amine curing agent, wherein the curing agent is apolyamine having a plurality of N—H linkages capable of reacting withthe epoxy resin; (ii) a desired amount of at least one hydraulic cementpowder; (iii) a desired amount of at least one type of hollow spheres;and (c) the first component and second component being mixed in a ratioto provide a coating composition having 0.20 to 0.90 parts water to 1.00part of hydraulic cement, wherein the coating composition forms coatingshaving a thickness of from approximately 2 mils to approximately 15mils.